Process for erecting folding slab construction

ABSTRACT

A building structure and construction process in which four or more individual slabs are formed and hingeably joined in coplanar relation. Thereafter the slabs are simultaneously raised, folded and braced in an erect position to form an enclosed structure having angularly inclined ridges and valleys along the folded seams.

lll! 3,593,482

United States Patent 52/745 along the folded seams.

PATENTEU JUL20 |971 SHEU 1 0F 4 INVENTOR.

DELP W. JOHNSON ATTORNEYS PATENTEDJULQOIQH SHEET 2 UF 4 nvvzw'roR.` DELP W JOHNSON ATTORNEYS PMENTEnJuLemsn 3,593,482

SHEU u 0F a FIG 8b INVENTOR.

DELP W. JOHNSON ATTORNEYS PROCESS Fort ERECTING FOLDING SLAB CONSTRUCTION This invention relates to buildings having prefabricated elements. More particularly, a buildingstructure and construction processare set forth for fabricating a building element such as a roof from foldably joined coplanar slabs, merely by lifting, folding and bracing the slabs in their erect position.

This invention is an improvement on the Integrated Folding Slab Construction set forth in my copending application Ser. No. 651,166, filed July 5, 1967, now Pat. No. 3,493,092. This copending application sets forth an apparatus and construction process wherein at least two panels are foldably joined by an embedded bendable member. Erection of the panels is accomplished by liftingand folding the panels to their erect disposition.

As distinguished from my prior invention, the present application sets forth a building apparatus and construction technique wherein the slabs or panels of the building structure are completely joined at all'seamswhile in coplanar relation. When raised, the slabs move from their coplanar disposition to an erect, folded, and angular position wherein they mutually define an enclosed building structure. The folded seams together define a series of angular-.ly inclined ridges, hips and valleys which together impart strength, stability and integrity to the finished structure.

An object of this invention is to foldably join the slab elements of a building structure in coplanar relation and thereafter to simultaneously lift, fold, and brace all the slabs as joined into a building structure of strength, stability and integrity. Accordingly, a group of' slabs are mutually joined together in coplanar relation. Each slabl has at least two straight edge boundaries defined by lines diverging from a common point and is hingeably joined to a contiguous slab at each of these boundaries along a foldable seam. At least one of the seams is designed to fold to form a valley and at least three of the remaining seams are designed to fold to form ridges. The slabs, as joined, are lifted, folded, and braced in the erect position to form an enclosed building structure.

An advantage of this invention is that all slabs of the building structure are simultaneously raised to the erect position, dispensing with the need for handling each slab individually.

A further advantage of this invention is that all slabs are joined together before they are erected. As the building structure is raised lto its erect position, no further joinder of the slabs is necessary.

An additional advantage of this invention is that no temporary bracing or framework is needed during erection of the building structure.

A still further advantage of this invention is that the joined slabs are self-positioning as raisedr and folded to form the completed building structure.

An additional advantage of this invention is that the slabs, as foldably joined, mutually resistv their tendency to break or buckle and converge at their respective ridges, hips and valleys to a common point or points forming lines of structural stiffness in the building structure.

An additional advantage of this invention is that a galaxy of aesthetically pleasing three-dimensional roof and building structures can be formed using the building technique and apparatus of this invention.

A further advantage of this building structure is that 'the wall, roof and floor slabs of an entire building can be fonned in parallel relation and thereafter the wall and roof slabs simultaneously erected.

Other objects, features and advantages ofthe present invention will be more apparent after referring to the following specification and attached drawings in which:

FIG. l is a plan view of a roof fabricated in accordance with the principles of this invention, this roof here being shown with attached walls for simultaneous erection of a completed building;

FIG. 2 is a side elevation section along lines 2-2 of FIG. 1, showing the roof overlying the walls and floor slab of the building;

FIG. 3 is a perspective view ofthe roof of' this invention raised into an erected position with the attached walls bracing the roof slabs in their folded and erected disposition;

F IG. d is a detail of rigging used in raising the building structure;

FIGS. 5a and 5b are details of the roof ridge or hip before and after erection of the building structure respectively;

FIGS. 6a and 6b are details of the roof valley before and after erection ofthe building structure;

FIGS. 7a, 7b and 7c are details of the wall, roof and floor slabs of the building structure in which:

7a shows the roof, wall and floor slab before erection;

7b shows the wall and roof slab after erection; and,

7c shows the wall and floor slab after erection;

FIGS. 8a and 8b are perspective views of an alternate building structure incorporating the invention in which:

8a shows the joined slabs in coplanar relation; and,

8b shows the joined slabs as erected.

With reference to FIGS. l and 2, structure A of this invention is shown including eight slabs or panels B joined along foldable seams C in coplanar relation for forming a roof. Hingeably joined to the lower surface of panels B for ultimate support and bracing of the structure A in its folded and raised position are eight wall sections D. Underlying the slabs of the' integral roof structure A is a fioor slab E.

Slabs B are elevated from the coplanar disposition of FIGS. i and 2 into tbe erected and folded disposition of FIG. 3 by a lifting apparatus F. As elevated, the slabs fold along their foldable seams C so that roof structure A folds into a threedimensional erect disposition. Attached walls D are gravitationally biased downward relative to the folded position of roof structure A, and when fastened to floor slab E, support and brace slabs B of roof structure A in their erected position.

With specific reference to FIGS. l and 2, slabs B are typically poured in forms with interconnecting bendable reinforcement elements extending between the forms. Concrete is poured into the forms and cured to form slabs. When the slabs are raised free of the forms, they are foldably joined. This process of foldably joining individual slabs of concrete is set forth with more particularlity in my copending application, Integrated Folding Slab Construction," Ser. No. 651,166, filed July 5, i967, now Pat. No. 3,493,092.

Slabs B are here shown forming together a rectangular plane iid. This plane is segmented by a series of eight foldable seams emanating from point 16, here shown at the central portion of plane. Foldable seams C emanate along straight lines diverging outwardly from point 16 to form diagonal seams 17 and axial seams 18. The seams together divide the rectangular plane of the joined slabs into a series of eight triangularly shaped slabs B.

As can be seen from the erected position of the structure illustrated in FIG. 3, diagonal seams 17 form the valleys of the completed roof structure and axial seams 18 form the ridges of the completed roof structure. The seams between slabs must be made in anticipation of these ridge and valley folds.

Referring to the detail of FIG. Sa, an axial seam 18 between two adjoiningl slabs B, is illustrated. The slabs are typically fabricated with numerous yreinforcing bars 22 extending between and across the seams l. The slabs have a contiguous interface 2d which extends from the top surface of slabs B downwardly to the medial point 25 of the slab. At medial point 2S, tbe edges of the slab diverge angularly outward at two opposed fold surfaces 26.

when the slabs are raised and folded as hingeably joined by reinforcing rods 22, interface 24 opens and opposed fold surfaces 26 close. As can be seen, once surfaces 26 close, the slabs are foldably joined in their new angular position and further angular movement of the slabs B with respect to one another is resisted by the compression of the abutted surfaces 26 and tension exerted across the interconnecting reinforcing bar 22. (This yinteraction of the hinged joint being set forth with more particularity in my above-referenced copending application).

It will be noted that the slabs pivot along their folded seams at fold line 25 located in the middle of the slabs at their folded seam. Construction of the slabs F folded at such a juncture is preferred for simplification in computation of the finished building dimensions. It will be appreciated, however, that fold line 25 does not necessarily have to be located along the medial portion of each slab but can be moved upwardly or downwardly relative to the .middle of the slab, as desired.

As shown in FIG. 5b, the separation of interface 24 along the ridge fold leaves a V-shaped groove between the adjoined slabs B, which groove can subsequently be filled with a sealant 28 to effect a watertight closure between the adjoined slabs B in their erected position.

With brief reference t0 FIGS. 6a and 6b, a diagonal or valley seam 17 is illustrated in the coplanar and erect position, respectively. Diagonal seam 17 has a closed interface 24' between the lower halves of the adjoined slabs B and a diverging opposed fold surfaces 26' separating the upper half of the adjoined slabs B. When the slabs are folded, the surfaces 26' close to form a solid interface between the adjoining slabs whereas lower interface 24' opens. lt is thus seen that seam 17 is precisely analogous to seam 18, the only exception being that the conjoined slabs fold in opposite angular directions.

With reference to FIG. 3, the roof structure A with its depending walls D is shown immediately after being raised to the erect position by a spreader 34 and attached rigging 35. Spreader 34 is in turn lifted by lifting apparatus (not shown).

Regarding spreader 34, this is typically a rectangular l beam structure formed with crossbracing (not shown) as necessary to maintain the relation between the sides 36. Each spreader side has ltwo separate riggings 35 extending downwardly and adjoined at their lower ends each to a slab B. Spreader 34 simultaneously lifts all slabs B of structure A and permits the slabs to gravitationally fold to their erect angular relation along their respective valley and ridge seams 17 and 18.

With reference to FIG. 4, the rigging attachment between one of the spreader sides 36 and a single slab B is illustrated. Typically, three upper blocks 38 are each supported from a point on a spreader side 36 immediately overlying the central portion of each slab B. Similarly, three lower blocks 40 attach in preselected spatial relation about the center of the slab at attachment pads 42 formed within slab B by means weli known. A single endless running strand of cable 43 is looped between the respective blocks so as to form six supporting strands for lifting eachslab B. As the strand is endless and looped over blocks on the spreader end and slab end of rigging 35 respectively, angular movement of the slabs during raising will be permitted by cable 43 running through the blocks 38 and 40. Adjustment of the length of running cable 43 extending to each slab B is provided by an adjustable splice 45.

The slabs as joined in coplanar relation, will simultaneously fold and position themselves with respect to one another in their erected disposition. Once this has been done, the slabs only need to be braced in their erected disposition to prevent their gravitational return or pancaking to the original coplanar position. Such bracing here is accomplished by fastening the depending walls D to floor slab E. Alternately, tie rods can be inserted interior of the structure between the adjoined slabs B.

The slabs, as braced, and foldably joined, impart structural strength and stability to the erected structure. It is known that when a single slab is horizontally disposed and extended over a large span, the slab will tend to break or buckle normally to the longitudinal axis of its span length. While each of the slabs here shown undergoes such a buckling force, this force is resisted by its foldably adjoined slabs in a manner similar to that of the respective angles of a piece of angle iron.

lt will be noted that all folded seams of the erected roof structure converge at apex or common point 25 in the central portion of structure A. This convergence imparts stability to the roof structure in that the folded seams together form lines of structural stiffness converging at the apex 25 of the completed roof structure.

Regarding the construction of apex 25, the static forces experienced at this point in the completed structure may exceed the structural strength of the materials used in formation of the panels. Accordingly, reinforcement of this point in the structure may be required. One form'of reinforcement suitable for use at the point includes a ball placed at apex 25 having mating sockets attached to each of the panels.

Roof structure A is shown braced in the erected position of FIG. 3 by attached depending walls D. As shown in the views of FIGS. l and 2, walls D typically are formed in parallel relation underlying each slab B. The walls are contiguous to a diagonal seam H7 at points 49 and are hingeably joined along gable lines S0 of the completed roof structure underlying each folded slabB. As can be seen, the top edge of each wall slab adjoining gable line 50 is sloped in anticipation of the pitch of the roof along the gable line. Further, each wall as hingeably joined to a slab B in parallel relation extends outwardly and angularly away from its slab B.

With reference to FIGS. 7a, 7b and 7c, the hingeable joinder of walls D to slabs B is shown in detail. Typically, floor slab E and wall slabs D are each poured and cured prior to the pouring and curing of slabs B. Floor slab E underlies the completed structure of the building and is provided at the outer perimeter thereof with a wall engaging step 56.

lt will be noted that wall slabs D lie outside of the plane of floor slab E when they are in their parallel unerected disposition. This folded disposition results from the fact that the respective gable lines to which the walls are attached lie outside of the perimeter of floor slab E when slabs B are in the coplanar disposition. When the building is erected, however, these gable lines overlie the perimeter of floor slab E, permitting the walls D to underlie the roof structure in supporting relation.

Each wall slab D, is provided with a hinge member 58,' one leaf of which is embedded interior of wall slab D when it is poured and cured and the other leaf of which protrudes upwardly and fastens to a slab B upon its subsequent pouring and curing. Typically, hinge 58 interconnects the outward corner of wall D with gable lines on the bottom surface of slab B. Hinge 58 is of the piano hinge variety and is embedded in both slabs B and D at numerous points therealong. This hinge permits the wall slab D to dependingly and pendulously swing thereabout to the erected position of the wall shown in FIG. 7b and 7c when the roof slabs B are raised to their erected position.

With reference to FIG. 7b, wall D is shown underlying slab B in a supporting relation. As slab B has been raised, wall D has been gravitationally and pendulously swung underlying slab D about hinge 58 until wall D is placed underlying the slab. As shown in FIG. 7c, the bottom portion of wall D is fastened interior of the wall engaging step 56 by bolted angle bar 60.

Once integral roof structure A has been raised to its erect position, and wall slabs D hingeably moved so as to underlie the erected slabs B in supporting relation, an integral roof structure A of strength, stability and integrity is formed. It should be noted that the folding and integrated slab construction of the present invention can be used with a galaxy of shapes, the only requirement being that the slabs, as joined, be foldable from a coplanar relation to an erected and folded relation without further joinder of any of the slabs along their seams when erected.

The buildingstructure illustrated in FIGS. l-3 is essentially symmetrical. This symmetry includes the slabs having equal angular intervals between their edges about point 25, having alternating ridges and valleys around point 25, and having the noncontiguous edges of the slabs conjoined by straight lines so as to form triangular polygons. lt should be apparent, that while a symmetrical construction is aesthetically pleasing and therefore preferred, this ,invention does not Vrequire such symmetry. Accordingly, the seams can be` l separated by unequal angular intervals. Further, the ridges and valleys can be arranged around point 25 in a sequence which is not alternating. Finally, the noncontiguous edges or boundaries of the slabs can be given virtually any shaped boundary desired.

With reference to FIGS. 8a and 8b, an elementary folded structure using this invention is illustrated. As shown in FIG. 8a, four slabs B' are shown in coplanar relation forming together a singular generally rectangular plane. At a point 70, here shown located along the central longitudinal axis of the plane, foldable seams C' diverge outwardly to the boundaries of each slab. y

Regarding seams C', ridge seam 72 extends from point 70 along the central longitudinal axis of the common generally rectangular plane rearwardly of point 70 to the edge of the common plane formed by the adjoining slabs B. Two hip seams 73 and 74 extend from point 70 diverging outwardly to the forward comers of the common plane formed by the slabs. As can be seen in the erected disposition of the slabs, seams 72, 73 and 74 each fold in the same angular direction so as to form a downwardly disposed angle of less than 180 between their joined slabs B when the slabs are foldably erected as shown in FIG. 8b.

Extending from central point 70 to the forward edge ofthe common plane of the slab, there is a valley seam 76. As compared to ridge seam 72 and hip seams 73 and 74, valley seam 76 folds in an angularly opposed direction disposing the adjoined slabs B at an angle diverging upwardly and outwardly of less than 180 from the interior concavity fonned by the erected structure. As in the case of the structure of FIG. 3, all foldable seams will be fabricated in their coplanar disposition in anticipation of their mutual angular orientation upon erection of the seam.

Erection of the slabs from their coplanar disposition illus trated in FIG. 8a to their erected angular disposition illustrated in FIG. 8b is carried out in a manner precisely analogous as to that illustrated in FIG. 3. Once the slabs are foldably erected, they are braced as erected and form along their respective ridges, hips and valley lines of converging stiffness which impart to the erected structure stability and strength.

It should be apparent at this juncture that the building technique of the present invention can be utilized to form an unlimited number of building structures. Virtually any series of slabs which can be joined in coplanar relation and then elevated along folded seams to form an enclosed building structure will satisfy the requirements of this invention. It will be noted, however, that the particular construction noted in FIGS. 8a and 8b comprises the minimum number of slabs and folded ridge and valley seams possible within the teaching of this invention.

We claim:

l. A process for erecting a building structure comprising: forming a series of four or more concrete roof slabs in coplanar relation each slab having two side edges diverging along straight lines from a common point and encircling said common point; simultaneously with said forming step foldably hinging each said roof slabs to two adjoining roof slabs along folding seams disposed along said straight lines diverging from said common point to encircle said common point with said foldably hinged slabs; attaching lift means to at least one of said slabs, said lift means being so positioned adjacent said common point that upon lifting said hinged slabs by said lift means said lifting provides folding at leastkone of said folding seams in a first angular direction; and further provides, simultaneously with folding of said one of said seams, folding at least three of said seams in a second angular direction opposite to said first angular direction; lifting said hinged slabs by said lifting means bracing said slabs as folded to maintain a building roof of strength, integrity and stability, and removing said lift means.

2. The process of claim l including the additional steps of:

forming concrete wall slabs with said roof slabs and hingeably conjornrng said wall slabs to said roof slabs; whereby said roof slabs when lifted permit said wall slabs to move pendulously to underlie said roof slabs in supporting relation.

3. The process of claim l including the additional step of: forming a floor slab underlying said roof slabs; and bracing said roof slabs as folded with respect to said floor slab.

d. The process of claim 3 and wherein said bracing step includes: forming wall slabs between said roof slabs and said floor slabs; hingeably conjoining said wall slabs to said roof slabs; raising said roof slabs to permit said wall slabs to move pendulously to underlie said roof slabs in supporting relation; and, fastening said wall slabs to said floor slabs to support said wall slabs as folded.

5. The process of claim l wherein said straight lines are disposed at equal angular intervals at about said point.

6. The process of claim l wherein said lifting step provides the folding of said seams to provide alternating ridges and valleys about said point. j

7. The process of claim l wherein each of said slabs as formed is a polygon.

8. A process for erecting a building structure comprising: forming a concrete floor slab having side edges for receiving and bracing wall slabs thereto; forming concrete wall slabs in coplanar relation with said floor slab adjacent said floor slab; forming a series of four or more concrete roof slabs in coplanar relation overlying said floor and wall slabs with each roof slab including side edges defined along straight lines diverging from a common point; simultaneously with the formation of said roof slabs foldably hinging each roof slab to two adjoining roof slabs along folding seams disposed along straight lines diverging from said common point overlying said floor slab, said roof slabs as foldably hinged encircling said common point; simultaneously with said forming step of said roof slabs foldably hinging said wall slabs to said roof slabs; attaching lift means to at least one of said slabs; said lifting means being so positioned adjacent said common point that upon lifting said hinged slabs by said lift means said lifting provides raising said roof slabs to permit said wall slabs to move pendulously to underlie said roof slabs in supporting relation and`t`olding at least one of said straight edge seams between said roof slabs in a first angular direction and folding simultaneously at least three of said straight edge seams in a second angular direction opposite said first angular direction; lifting said hinged slabs by said lifting means, fastening said wall slabs to the edges of said floor slabs to maintain said wall slabs and roof slabs in erected relation, and removing said lift means. 

1. A process for erecting a building structure comprising: forming a series of four or more concrete roof slabs in coplanar relation each slab having two side edges diverging along straight lines from a common point and encircling said common point; simultaneously with said forming step foldably hinging each said roof slabs to two adjoining roof slabs along folding seams disposed along said straight lines diverging from said common point to encircle said common point with said foldably hinged slabs; attaching lift means to at least one of said slabs, said lift means being so positioned adjacent said common point that upon lifting said hinged slabs by said lift means said lifting provides folding at least one of said folding seams in a first angular direction; and further provides, simultaneously with folding of said one of said seams, folding at least three of said seams in a second angular direction opposite to said first angular direction; lifting said hinged slabs by said lifting means bracing said slabs as folded to maintain a building roof of strength, integrity and stability, and removing said lift means.
 2. The process of claim 1 including the additional steps of: forming concrete wall slabs with said roof slabs and hingeably conjoining said wall slabs to said roof slabs; whereby said roof slabs when lifted permit said wall slabs to move pendulously to underlie said roof slabs in supporting relation.
 3. The process of claim 1 including the additional step of: forming a floor slab underlying said roof slabs; and bracing said roof slabs as folded with respect to said floor slab.
 4. The process of claim 3 and wherein said bracing step includes: forming wall slabs between said roof slabs and said floor slabs; hingeably conjoining said wall slabs to said roof slabs; raising said roof slabs to permit said wall slabs to move pendulously to underlie said roof slabs in supporting relation; and, fastening said wall slabs to said floor slabs to support said wall slabs as folded.
 5. The process of claim 1 wherein said straight lines are disposed at equal angular intervals at about said point.
 6. The process of claim 1 wherein said lifting step provides the folding of said seams to provide alternating ridges and valleys about said point.
 7. The process of claim 1 wherein each of said slabs as formed is a polygon.
 8. A process for erecting a building structure comprising: forming a concrete floor slab having side edges for receiving and bracing wall slabs thereto; forming concrete wall slabs in coplanar relation with said floor slab adjacent said floor slab; forming a series of four or more concrete roof slabs in coplanar relation overlying said floor and wall slabs with each roof slab including side edges defined along straight lines diverging from a common point; simultaneously with the formation of said roof slabs foldably hinging each roof slab to two adjoining roof slabs along folding seams disposed along straight lines diverging from said common point overlying said floor slab, said roof slabs as foldably hinged encircling said common point; simultaneously with said forming step of said roof slabs foldably hinging said wall slabs to said roof slabs; attaching lift means to at least one of said slabs; said lifting means being so positioned adjacent said common point that upon lifting said hinged slabs by said lift means said lifting provides raising said roof slabs to permit said wall slabs to move pendulously to underlie said roof slabs in supporting relation and folding at least one of said straight edge seams between said roof slabs in a first angular direction and folding simultaneously at least three of said straight edge seams in a second angular direction opposite said first angular direction; lifting said hinged slabs by said lifting means, fastening said wall slabs to the edges of said floor slabs to maintain said wall slabs and roof slabs in erected relation, and removing said lift means. 